VPG VanWeigh Use and care manual

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VanWeigh®
Installation, Setup and Calibration Manual

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VanWeigh®

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Important installation information and liability
waiver
VPG designs and manufactures on-board vehicle weighing equipment. These installation
guidelines are provided solely for the use of trained installers and represent the correct, safe and
recommended method of installation.
These guidelines must be followed fully to ensure proper, safe installation. Failure to do so may
result in serious consequences including, but not limited to, failure of the system to function
properly and damage to the weighing equipment that could jeopardize the stability and safety of
the vehicle.
VPG accepts no responsibility or liability for consequences arising from any improper installation
of the weighing equipment including but not limited to, any misapplication or misinterpretation of
the installation information contained herein.
Strict observance of these guidelines should help to ensure accurate weight measurement and
enable safe operation of the vehicle. Failure of our on-board vehicle weighing equipment due to
poor installation workmanship or incorrectly installed elements remains solely the responsibility of
the installer.
VPG does not accept responsibility for the structural integrity of the vehicle concerned, for any
part thereof, and for its proper, safe operation.
The company also reserves the right to make any amendments and alterations to this document
deemed necessary. You should ensure you have the current version of this information by
contacting VPG prior to performing installation, such as on our website at www.vpgsensors.com
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Contents
Important installation information
and liability waiver 3
Introduction and scope 6
Scope 6
About this document 6
Document Control 6
Important installation information 7
Installation 9
Components 10
Tools 14
Installation overview 15
Typical system schematics 17
How to install the display unit 18
How to install the junction box 20
Connecting the cables 21
Sensor types 22
Sensor installation positions 23
Axle transducer on a front strut 24
Axle transducer on a leaf spring 25
Air pressure transducer 26
How to install a steel axle
transducer 27
How to install an air pressure
transducer 29
System Overview 33
VanWeigh® Display Unit Overview34
Display unit operation 35
Home Page 35
How to navigate the system 36
Editing Values 37
Configuration 39
The configuration menu 40
Login 41
Vehicle configuration 42
How to configure the junction box 43
How to configure the alarms 47
Weighing the Vehicle 48
How to calibrate the junction box 51
How to configure the display 54
How to configure a serial output 56
How to configure the weighing units 57
How to configure the PIN Numbers 58
System info and Diagnostics
59
System Info 60
Diagnostics 63
Appendix A 67
System configuration table 68
Zero and span weights tables 69
Zero weights: 69
Span weights: 69
Appendix B 71
VanWeigh display Molex Microfit 24-
way connector 72
Appendix C 73
VanWeigh II Specification 74
Appendix D 77
Warning and Status Messages 78
Alarm / Warning Icons 80
Message/Log Error Code Text 81
VanWeigh®

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VanWeigh®VanWeigh®

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Introduction and scope
VanWeigh® is an overload monitoring system for use on twin axle vehicles with mechanical or air
suspension systems.
Scope
This document is intended as a guide to the installation and commissioning of VanWeigh®.
It covers two transducer types currently supported in a VanWeigh® system:
• VanWeigh® axle transducers. These measure suspension deection on mechanical spring
suspension systems
• Air pressure transducers. These measure changes to air pressure on air suspension systems
Di󰀨erent system congurations can be used to support di󰀨erent chassis types. The system can be
congured to use either type of transducer and any combination of the two.
About this document
Any display screenshots used in this document are intended as an illustration of the function being
described. As such, any specic detail or settings shown will di󰀨er from one installation to another.
The documentation uses the following conventions:
Important. These are important notes and appear inside a green border
Caution. These notes warn of an operation that may cause damage to the VanWeigh®
system. These notes appear inside an orange border
Warning. These notes warn of an operaon that may cause injury to the installer. The note is
highlighted in a yellow banner
Document Control
Document Version: Date: Version Notes:
v1.0 8 Mar 2019
v2.0 11 Sept 2019 Software Update Sept 2019
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Important installation information
Please read this installation guide completely to ensure that all instructions are fully
understood before you install VanWeigh®
To ensure a reliable and properly functioning system particular importance should be paid to the
following:
• VanWeigh® axle transducer installation.A suitable location for the transducer should be
carefully identied and that location should then be prepared for the transducer to be attached.
See “How to install a steel axle transducer” on page 27
• VanWeigh® axle transducer orientation.Axle transducers must be mounted to the vehicle in
the correct orientation. See “How to install a steel axle transducer” on page 27
• Accurate recording of sensor serial numbers in their sensor positions. It is recommended that
you use the system conguration table to record this information and refer to it when you are
conguring the system. See “System conguration table” on page 68
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VanWeigh®

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Installation
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Components
Below is a list of components that can be used in a VanWeigh® installation.
Check that you have all of the appropriate components for your installation before starting.
Images are for illustration purposes only. Later versions may di󰀨er.
VanWeigh® Display Unit
A single VanWeigh® display unit is
supplied for the vehicle
Part No: 551430
Display Mount
A single display mount is supplied
for the display unit
Part No: 551430-MOUNT
Axle Transducer
A single cable with a connector at
one end and the axle transducer
at the other
This is supplied for steel axle
suspension systems.
A single transducer is supplied
for each transducer position. See
“Sensor installation positions” on
page 23.
Bonding tape is supplied for each
transducer
Part No: DRG-106009
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Air Pressure Transducer
The parts for the air pressure
transducer are supplied in a bag.
A single air transducer is made up
from a T-connector, a brass sensor
tting and two plastic air pipe
ttings
This is supplied for air suspension
systems
A single transducer is supplied
for each transducer position. See
“Sensor installation positions” on
page 23.
Part No: 996210C (For air pipe
outside diameter 8mm & 10mm)
Part No: 542549 (Air sensor only)
Internal Domain Cable with Air
Transducer Fitting
A single transducer cable is
supplied for each air transducer
position. See “Sensor installation
positions” on page 23.
Part No: DRG-106001
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Junction Box
A single junction box is supplied
for the rigid vehicle
Part No: 341410
Internal Domain Junction Box
Cable 3 way
The cable is identied by the
green junction box connector
and 3 male internal domain cable
connectors
Part No: DRG-106898
External/Internal Domain
Junction Box Cable 2 way
A single external domain output
cable is supplied for each junction
box
The cable is identied by the
brown junction box connector at
one end and at the other end, one
external domain cable connector
and one male internal domain
cable connector
Part No: DRG-106897
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External Domain/Power cable
A single external domain cable is
supplied for the system
The cable is identied by the
external domain cable connector
at one end and the display
connector at the other
Part No: DRG-106143
Cable Protector and Cable Ties
Cable protector is supplied and
can be cut as required
Cable ties are also supplied
Part No: 493459
Surface Cleaning Wipes
Part No: 995627
Double Sided Bonding Tape
Part No: 995614
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Tools
Check that you have the following tools before starting an installation.
Tool Check
Screwdriver set
Hex driver set
Torx driver set
Socket set
Multimeter
Side cutters
Drill set
G-Clamp
Spanner set (including 18 mm and
24 mm)
Air pipe cutters
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Installation overview
Ensure the engine of the vehicle is o and the parking brake is applied before starng the
installaon
It is recommended that you use a mechanics pit inside a workshop to install the VanWeigh®
system
The VanWeigh® display unit is used to display sensor information once the system has been
installed, congured and calibrated.
The display unit is connected to the junction box via the external domain cable. The junction box
is installed on the chassis of the vehicle and is connected to all four sensors on the vehicle. The
sensors and junction box form the internal domain.
The sensors send information back to the junction box. The junction box then transmits
information back to the display unit via the external domain.
External domain
Internal domain
Display Unit
Junction
box
Sensor
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There are three main steps to installing the VanWeigh® system:
• Install the display unit. The display unit must be installed in the cab of the vehicle and
connected to the vehicles power supply. The external domain cable must be routed from the
display unit to the junction box. See “How to install the display unit” on page 18.
• Junction box installation. This must be installed on the chassis of the vehicle. It must be
located in an appropriate position between the suspension systems and the cab of the vehicle.
The sensor and display unit cables must be able to reach the junction box.
• Sensor installation. The type of sensors you install will depend on the suspension systems in
operation on the vehicle. Air pressure transducers are installed on air suspension systems.
Axle transducers are installed on steel axle suspension systems. The sensors must be
installed in an appropriate position on the suspension system and their cables must be routed
back to the junction box.
It is recommended that the display unit is installed rst, followed by the junction box and
sensors. However, these steps can be performed in any order.
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Typical system schematics
Below are two examples of system schematics showing where the junction box and transducers
are tted in relation to the vehicle. These are two example schematics, but a variety of
congurations may be used.
Leaf Spring Air Spring
Truck Air
System
Truck Air
System
VanWeigh®
Display unit
Junction Box and
Axle Transducers
Suspension
Air Bags
Air
Transducers
Leaf Spring Leaf Spring
VanWeigh®
Display unit Junction Box and Axle Transducers
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How to install the display unit
A single display unit is installed in the cab of the vehicle to display the sensor information. The
display unit has a single port that connects to both the power supply on the vehicle and the
junction box, via the external domain cable.
The external domain cable starts in the cab of the vehicle and is routed to the power supply and
junction box.
1. Route the power cables on the display unit cable from the location of the display unit in the cab
to the appropriate connection point for the power supply in the vehicle
2. Route the external domain cable on the display unit cable from the the location of the display
unit in the cab to the location for the junction box
• Avoid running cables on or near sharp objects
• Keep cables away from hot components such as exhausts and engines
Use cable protector to protect the cable at positions where it may be exposed to damage
It is recommended that you follow existing cable routes and ensure that the cable is able to
plug into the rear of the display unit after it has been mounted
3. Mount the dashboard mount to the vehicle. Mount it to a position that does not obscure the
drivers line of sight when driving the vehicle. Ensure that the display unit cable can be routed
to the back of the display unit
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4. Connect the power cables to the appropriate connection point for the power supply in the
vehicle
• The system can be powered from 12V or 24V DC power supplies
• The system has an operating range of 9V to 36V DC
• Connect the white wire to the ignition to power the monitor on and o󰀨 when the ignition is
turned on or o󰀨
5. Plug the display unit cable into the rear of the display unit
6. Test the power connection
7. Mount the display unit into the dashboard mount
Connect to vehicle ignition supply (9-36V)
3A
3A
WHT (IGN)
BLU (0V)
BRN (+VE)
Power/Display
Unit Cable
DRG-106143
Connect to vehicle power supply (9-36V)
Connect to vehicle Ground
WIRING
OPTIONS
+ VE IGN. 0V RESULT
1 BROWN WHITE BLUE
THE DISPLAY WILL TURN ON BY THE IGNITION
KEY AND TURN OFF BY AUTO POWER OFF
CONFIGURATION OPTION
2
BROWN &
WHITE
BLUE
THE DISPLAY WILL TURN ON/OFF BY THE
IGNITION KEY OR THE STAND BY ICON WHEN
THE IGNITION IS ON
B
C
D
1 2
A
3
2 1 4
B
A
5 6
A4
C
D
4
6
5
3
WD7216
DRAWING No.
POWER SUPPLY WIRING DETAILS
TITLE:
G.C.
THIRD ANGLE PROJ.
MATERIAL:
ALL DIMS IN MM
UNLESS OTHERWISE
STATED
DRAWN:
No. OFF
VanWeigh 2
PROJECT NAME:
NTS
SCALE:
24.06.19.
DATE:
SURFACE FINISH
UNLESS
OTHERWISE STATED
THIS DRAWING/SPECIFICATION IS THE
PROPERTY OF VISHAY PM ONBOARD LIMITED
IT IS CONFIDENTIAL AND PROTECTED
BY COPYRIGHT. IT MUST NOT BE LOANED
COPIED, REPRODUCED OR COMMUNICATED
EITHER WHOLLY OR IN PART TO A THIRD
PARTY AND MUST NOT BE USED FOR ANY
PURPOSE DETRIMENTAL TO THE INTERESTS
OF VISHAY PM ONBOARD LIMITED WITHOUT
THEIR WRITTEN PERMISSION.
IF IN DOUBT ASK
TOLERANCES
NO DEC. PLCS 0.25mm
ONE DEC. PLC
0.10mm
TWO DEC. PLCS
0.05mm
ANGLES
2 DEG.
REV.
PART No. PAGES:
1 OF 1
0
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How to install the junction box
A single junction box is used to receive information from each sensor in a suspension system.
1. Select a position to install the junction box where:
• The junction box cannot be damaged by any moving parts on the vehicle
• The cables from each sensor can reach the junction box. Ensure the cables can be routed
from the transducer without risk of damage from any moving parts on the vehicle
• The external domain cable can reach from the cab of the vehicle to the junction box.
Ensure the cable can be routed to the cab without risk of damage from any moving parts
2. Mount the junction box to the vehicle:
• The cable sockets must point to the rear of
the vehicle
The VanWeigh® system will not provide the
correct measurements if the junction box is
not mounted with the cable sockets pointing
to the rear of the vehicle
• Use existing holes on the chassis to mount
the junction box, if possible. Drill holes
appropriate to the size and length of the
mounting screws if existing holes are not
suitable
• Use 2 X 1/4” or M6 screws with Nyloc nuts
to mount the junction box. The length of the
screws may vary depending on where you
mount it
3. Make a note of the orientation of the top face of the junction box, e.g. facing up, down, left or
right side of the vehicle. In the example shown above, the junction box is facing down
It is recommended that you use the system conguration table to record this information.
See “System conguration table” on page 68
VanWeigh®